Integrated current collector for electric vehicle battery cell

ABSTRACT

Systems and methods to power an electric vehicle are provided. The system can include a battery pack having a plurality of battery modules, each of the of battery modules can include a plurality of battery blocks. The battery blocks can include a plurality of cylindrical battery cells. An integrated current collector device can be formed in a single structure and coupled with the plurality of cylindrical battery cells. The integrated current collector device can include a first current collector to couple with positive terminals of the cylindrical battery cells at first ends of the cylindrical battery cells and a second current collector to couple with negative terminals of the cylindrical battery cells at the first ends of the cylindrical battery cells. An isolation layer can be disposed between the first current collector and the second current collector to electrically isolate the first current collector from the second current collector.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Provisional Application 62/557,681, titled “INTEGRATEDCURRENT COLLECTOR”, filed on Sep. 12, 2017. The entire disclosure ofwhich is incorporated herein by reference in its entirety.

BACKGROUND

Vehicles such as automobiles can include power sources. The powersources can power motors or other systems of the vehicles.

SUMMARY

In at least one aspect, a system to power electric vehicles. The systemcan include a battery pack to power an electric vehicle. The batterypack can include a plurality of battery modules. Each of the pluralityof battery modules can include a plurality of battery blocks. A firstbattery block of the plurality of battery blocks can include a pair ofbattery block terminals. The first battery block can include a pluralityof cylindrical battery cells. Each of the plurality of cylindricalbattery cells can include a positive terminal and a negative terminal.An integrated current collector device can be formed in a singlestructure. The integrated current collector device can include a firstcurrent collector having a conductive layer. The conductive layer of thefirst current collector can couple the first current collector withpositive terminals of the plurality of cylindrical battery cells atfirst ends of the plurality of cylindrical battery cells. A secondcurrent collector can include a conductive layer. The conductive layerof the second current collector can couple the second current collectorwith negative terminals of the plurality of cylindrical battery cells atthe first ends of the plurality of cylindrical battery cells. Anisolation layer can be disposed between the first current collector andthe second current collector. The isolation layer can electricallyisolate the first current collector from the second current collector.The isolation layer can bind the first current collector with the secondcurrent collector to form the single structure of the integrated currentcollector. The integrated current collector can provide structuralsupport to hold the plurality of cylindrical battery cells in placerelative to one another when the plurality of cylindrical battery cellsare electrically connected with the first current collector and thesecond current collector.

In another aspect, a method of providing a system to power electricvehicles is provided. The method can include providing a battery pack topower an electric vehicle. The battery pack can include a plurality ofbattery modules. Each of the plurality of battery modules can include aplurality of battery blocks. A first battery block of the plurality ofbattery blocks can include a pair of battery block terminals. The methodcan include disposing a plurality of cylindrical battery cells in thefirst battery block. Each of the cylindrical battery cells can include apositive terminal and a negative terminal. The method can includeforming an integrated current collector device via injection molding.The integrated current collector device can include a first currentcollector, a second current collector, and an isolation layer disposedbetween the first current collector, a second current collector. Themethod can include electrically isolating, using the isolation layer,the first current collector from the second current collector in theintegrated current collector device. The method can include mounting theintegrated current collector device, including the first currentcollector, the second current collector, and the isolation layer, to theplurality of cylindrical battery cells. The integrated current collectordevice can provide structural support to hold the plurality ofcylindrical battery cells in place relative to one another. The methodcan include electrically connecting the first current collector topositive terminals of the plurality of cylindrical battery cells atfirst ends of the plurality of cylindrical battery cells. The method caninclude electrically connecting the second current collector to negativeterminals of the plurality of cylindrical battery cells at the firstends of the plurality of cylindrical battery cells.

In another aspect, a method of providing a system to power electricvehicles is provided. The system can include a battery pack to power anelectric vehicle. The battery pack can include a plurality of batterymodules. Each of the plurality of battery modules can include aplurality of battery blocks. A first battery block of the plurality ofbattery blocks can include a pair of battery block terminals. The firstbattery block can include a plurality of cylindrical battery cells. Eachof the plurality of cylindrical battery cells can include a positiveterminal and a negative terminal. An integrated current collector devicecan be formed in a single structure. The integrated current collectordevice can include a first current collector having a conductive layer.The conductive layer of the first current collector can couple the firstcurrent collector with positive terminals of the plurality ofcylindrical battery cells at first ends of the plurality of cylindricalbattery cells. A second current collector can include a conductivelayer. The conductive layer of the second current collector can couplethe second current collector with negative terminals of the plurality ofcylindrical battery cells at the first ends of the plurality ofcylindrical battery cells. An isolation layer can be disposed betweenthe first current collector and the second current collector. Theisolation layer can electrically isolate the first current collectorfrom the second current collector. The isolation layer can bind thefirst current collector with the second current collector to form thesingle structure of the integrated current collector. The integratedcurrent collector can provide structural support to hold the pluralityof cylindrical battery cells in place relative to one another when theplurality of cylindrical battery cells are electrically connected withthe first current collector and the second current collector.

In another aspect, an electric vehicle is provided. The electric vehiclecan include a battery pack to power an electric vehicle. The batterypack can include a plurality of battery modules. Each of the pluralityof battery modules can include a plurality of battery blocks. A firstbattery block of the plurality of battery blocks can include a pair ofbattery block terminals. The first battery block can include a pluralityof cylindrical battery cells. Each of the plurality of cylindricalbattery cells can include a positive terminal and a negative terminal.An integrated current collector device can be formed in a singlestructure. The integrated current collector can include a first currentcollector having a conductive layer. The conductive layer of the firstcurrent collector can couple the first current collector with positiveterminals of the plurality of cylindrical battery cells at first ends ofthe plurality of cylindrical battery cells. A second current collectorcan include a conductive layer. The conductive layer of the secondcurrent collector can couple the second current collector with negativeterminals of the plurality of cylindrical battery cells at the firstends of the plurality of cylindrical battery cells. An isolation layercan be disposed between the first current collector and the secondcurrent collector. The isolation layer can electrically isolate thefirst current collector from the second current collector. The isolationlayer can bind the first current collector with the second currentcollector to form the single structure of the integrated currentcollector. The integrated current collector can provide structuralsupport to hold the plurality of cylindrical battery cells in placerelative to one another when the plurality of cylindrical battery cellsare electrically connected with the first current collector and thesecond current collector.

These and other aspects and implementations are discussed in detailbelow. The foregoing information and the following detailed descriptioninclude illustrative examples of various aspects and implementations,and provide an overview or framework for understanding the nature andcharacter of the claimed aspects and implementations. The drawingsprovide illustration and a further understanding of the various aspectsand implementations, and are incorporated in and constitute a part ofthis specification.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are not necessarily intended to be drawn toscale. Like reference numbers and designations in the various drawingsindicate like elements. For purposes of clarity, not every component maybe labelled in every drawing. In the drawings:

FIG. 1 depicts an illustrative embodiment of a system to power anelectric vehicle;

FIG. 2 depicts an exploded view of an illustrative embodiment of asystem to power an electric vehicle;

FIG. 3 depicts a top view of an illustrative embodiment of a system topower an electric vehicle;

FIG. 4 is a block diagram depicting a cross-sectional view of an exampleelectric vehicle installed with a battery pack;

FIG. 5 is a flow diagram depicting an illustrative embodiment of amethod for providing a system to power an electric vehicle; and

FIG. 6 is a flow diagram depicting an illustrative embodiment of amethod for providing a system to power an electric vehicle.

DETAILED DESCRIPTION

Following below are more detailed descriptions of various conceptsrelated to, and implementations of, methods, apparatuses, devices, andsystems to battery packs to power electric vehicles. The variousconcepts introduced above and discussed in greater detail below may beimplemented in any of numerous ways.

The systems and methods for providing power to electric vehiclesdisclosed herein describe a battery pack that can reside in or bedisposed within an electric vehicle to provide power to the electricvehicle. The battery pack can include a plurality of battery modules.The plurality of battery modules can include a plurality of batteryblocks. The battery blocks can include a plurality of cylindricalbattery cells. Each of the plurality of cylindrical battery cells caninclude a positive terminal and a negative terminal that couple with anintegrated current collector device. The integrated current collectordevice can include positive and negative current collectors embedded inthe integrated current collector device to provide single-step directwelding. For example, the integrated current collector device asdescribed herein can provide positive and negative current collectorscoupled at the same end or surface of each of the batter cells. Thus,the positive and negative connections can be made from the same end orsurface of each of the battery cells to the positive and negativecurrent collectors, respectively, of the integrated current collectordevice.

By mounting or coupling the integrated current collector device havingboth positive and negative current collectors to the same end or surfaceof each of the battery cells, the assembly process can be simplified anddefects introduced during assembly, for instance, can be reduced. Forexample, battery pack assembly can involve numerous parts which can makeassembly and manufacturing difficult. Consider that the defect rate forautomotive battery packs can be 25 parts per million (PPM), where 1PPM=1 defect/1,000,000 for instance. It can be challenging to improvebattery pack manufacturing, given that current collectors areelectrically connected to battery cells by welding or wire-bonding.Handling of active electrical components, such as during hand assemblyin high voltage applications, can involve or entail much caution. Thebattery packs described herein include cylindrical battery cells coupledwith an integrated current collector device having a positive currentcollector and a negative current collector. The integrated currentcollector devices can decrease part count, lower PPM and increases partquality. The embedded sense lines can provide for battery monitoringduring welding, identify issues and defects at an early stage ofassembly.

FIG. 1, among others, depicts a battery module 100 having two batteryblocks 105 (e.g., a first battery block 105 and a second battery block105). The first and second battery blocks 105 can be subcomponents ofthe battery module 100. The battery module 100 can refer to a batterysystem having multiple battery blocks 105 (e.g., two or more). Forexample, multiple battery blocks 105 can be electrically coupled witheach other to form a battery module 100. The battery modules 100 can beformed having a variety of different shapes. For example, the shape ofthe battery modules 100 can be determined or selected to accommodate abattery pack within which a respective battery module 100 is to bedisposed. The shape of the battery modules 100 may include, but notlimited to, a square shape, rectangular shape, circular shape, or atriangular shape. Battery modules 100 in a common battery pack can havethe same shape. One or more battery modules 100 in a common battery packcan have a different shape from one or more other battery modules 100 inthe common battery pack.

The number of battery blocks 105 in a battery module 100 can vary andcan be selected based at least in part on an amount of energy or powerto be provided to an electric vehicle. For example, the battery module100 can couple with one or more bus-bars within a battery pack or couplewith a battery pack of an electric vehicle to provide electrical powerto other electrical components of the electric vehicle.

The battery module 100 can include multiple battery blocks 105. Thebattery module 100 can include multiple cell holders (e.g., first cellholder 225 and second cell holder 230 of FIG. 2) to hold or couple thebattery blocks 105 together, and to couple the battery cells 110 to formthe battery blocks 105 together. Battery blocks 105 can be held togetherusing one or more cell holders 225, 230. For example, a single one ofcell holders 230, 235 can house at least two battery blocks 105 in asingle plastic housing. The battery cells 110 can be positioned withinthe respective one of the cell holder 230, 235 using adhesive material(e.g., 2-part epoxy, silicone-based glue, or other liquid adhesive),heat staking, or press fit. The battery cells 110 can be positionedwithin the respective one of the cell holder 230, 235 to hold them inplace. For example, the battery cells 110 can have a tolerance in heightas part of the manufacturing process. This tolerance can be accountedfor by locating either the top or bottom of the respective battery cells110 to a common plane and fixing them there within the respective one ofthe cell holder 230, 235. For example, a bottom end of each of thebattery cells 110 can be positioned flat relative to each other toprovide a flat mating surface to a cold plate. The top end of thebattery cells 110 can be positioned flat relative to the first cellholder 230 to provide or form a flat plane for forming battery cell tocurrent collector connections (e.g., wirebonding, laser welding). Theflat plane may only be provided on a top or bottom plane of the batterycells 110 because the cell holders 230, 235 can be retained in therespective battery module 100 using adhesive material (e.g., 2-partepoxy, silicone-based glue, or other liquid adhesive), bolts/fasteners,pressure sensitive adhesive (PSA) tape, or a combination of thesematerials. The structure of the battery module 100 that the cell holders230, 235 are placed in or disposed in can include a stamped, bent, orformed metal housing or could be a plastic housing made by injectionmolding or another manufacturing method.

The first and second battery blocks 105 include a plurality of batterycells 110. The battery cells 110 can be homogeneous or heterogeneous inone or more aspects, such as height, shape, voltage, energy capacity,location of terminal(s) and so on. The first battery block 105 mayinclude the same number of battery cells 110 as the second batteryblock, or the first battery block 105 may have a different number ofbattery cells 110 (e.g., greater than, less than) the second batteryblock 105. The first and second battery blocks 105 can include anynumber of battery cells 110 arranged in any configuration (e.g., anarray of N×N or N×M battery cells, where N, M are integers). Forexample, a battery block 105 may include two battery cell 110 or fiftybattery cells 110. The number of battery cells 110 included within abattery block 105 can vary within or outside this range. The number ofbattery cells 110 included within a battery block 105 can vary based inpart on battery cell level specifications, battery module levelrequirements, battery pack level requirements or a combination of thesethat you are trying to obtain or reach with the respective battery block105.

The number of battery cells 110 to include in a particular battery block105 can be determined based at least in part on a desired capacity ofthe battery block 105 or a particular application of the battery block105. For example, a battery block 105 can contain a fixed “p” amount ofbattery cells, connected electrically in parallel which can provide abattery block capacity of “p” times that of the single battery cellcapacity. The voltage of the respective battery block 105 (or cellblock) can be the same as that of the single battery cell 110 (e.g., 0Vto 5V or other ranges), which could be treated as larger cells that canbe connected in series into the battery module 100 for battery packs forexample. For example, the plurality of cylindrical battery cells 110 canprovide a battery block capacity to store energy that is at least fivetimes greater than a battery cell capacity of each of the plurality ofcylindrical battery cells 110. The battery blocks 105 can have a voltageof up to 5 volts across the pair of battery block terminals of therespective battery block 105.

The battery blocks 105 can each include one or more battery cells 110and each of the plurality of battery cells 110 can have a voltage of upto 5 volts (or other limit) across terminals of the correspondingbattery cell. For example, the battery blocks 105 can include anarrangement of a plurality of battery cells 110 electrically connectedin parallel. Each cell of the plurality of battery cells can bespatially separated from each of at least one adjacent cell by, forexample, two millimeter (mm) or less. The arrangement of the pluralityof battery cells can form a battery block 105 for storing energy and canhave a voltage of up to 5 volts across terminals of the respectivebattery block 105.

For instance, a single battery cell 110 can have a maximum voltage of4.2V, and the corresponding battery block 105 can have a maximum voltageof 4.2V. For example, a battery block 105 using 5 volts/5 Ampere-hour(5V/5 Ah) cells with 60 cells in parallel can become a 0V to 5V, 300 Ahmodular unit. The battery block 105 can have high packaging efficiencyby utilizing the most efficient minimum cell to cell spacing (e.g., anyvalue from 0.3 mm to 2 mm) that prevents thermal propagation within theblock with each cell having an individual and isolated vent port forinstance. For example, spatial separation between adjacent cells of lessthan 1 mm can be implemented in the present battery blocks 105. Thebattery block 105 can thus be small, e.g., less than 0.05 cubic feet,giving it a high volumetric energy density for high packing efficiency.

The battery block 105 can include battery cells 110 physically arrangedin parallel to each other along the longest dimension of each batterycell 110. The battery cells 110 can be arranged physically as a twodimensional array of battery cells 110 (e.g., as shown in FIGS. 1-3), orcan be arranged physically as a three dimensional array of battery cells110. For example, the battery cells 110 can be arranged in an arrayformation having three values, such as a length value 160, a heightvalue (or depth value) 165, and a width value 170 to form the batteryblock 105 or battery module 100. As depicted in FIG. 1, the batterymodule 100 can have a dimension of length 160×width 170×height 165. Thebattery module 100 can have a length value 160 of 200 mm, a width value170 of 650 mm, and a height value 165 of 100 mm. The length 160 mayrange from 25 mm to 700 mm. The width 170 may range from 25 mm to 700mm. The height value 165 (or depth) may range from 65 mm to 150 mm. Theheight 165 of the battery block 105 or battery module 100 may correspondto (or be dictated by) the height or longest dimension of a componentthe battery cell 110.

The plurality of battery cells 110 can be enclosed in the battery block105. The battery block 105 can be formed in a variety of differentshapes, such as but not limited to, a rectangular shape, a square shapeor a circular shape. The battery block 105 can be formed having a traylike shape and can include a raised edge or border region. The batterycells 110 can be held in position by the raised edge or border region ofthe battery block enclosure. The battery block 105 can be formed suchthat it at least partially surrounds or encloses each of the batterycells 110. The battery block 105 can be less than 1 cubic feet in volume(e.g., less than 0.15 cubic feet). For example, the battery block 105can be less than 0.05 cubic feet in volume.

The battery cells 110 can be provided or disposed in the first andsecond battery blocks 105 and can be arranged in one or more rows andone or more columns of battery cells 110. Each of the rows or columns ofbattery cells 110 can include the same number of battery cells 110 orthey can include a different number of battery cells 110. The batterycells 110 can be arranged spatially relative to one another to reduceoverall volume of the battery block 105, to allow for minimum cell tocell spacing (e.g., without failure or degradation in performance), orto allow for an adequate number of vent ports. The rows of battery cells110 can be arranged in a slanted, staggered or offset formation relativeto one another (see FIG. 3). The battery cells 110 can be placed invarious other formations or arrangements.

Each of the battery cells 110 in a common battery block 105 (e.g., samebattery block 105) can be spaced from a neighboring or adjacent batterycell 110 in all directions by a distance that ranges from 0.5 mm to 3 mm(e.g., 1.5 mm spacing between each battery cell 110, 2 mm spacingbetween each battery cell 110). The battery cells 110 in a commonbattery block 105 can be uniformly or evenly spaced. For example, eachof the battery cells 110 can be spaced the same distance from one ormore other battery cells 110 in the battery blocks 105. One or morebattery cells 110 in a common battery block 105 can be spaced one ormore different distances from another one or more battery cells 110 ofthe common battery block 105. Adjacent battery cells 110 betweendifferent battery blocks 105 can be spaced a distance in a range from 2mm to 6 mm. The distances between the battery cells 110 of differentbattery blocks 105 can vary across applications and configurations, andcan be selected based at least in part on the dimensions of the batteryblocks 105, electrical clearance or creepage specifications, ormanufacturing tolerances for the respective battery module 100.

The battery block 105 can provide a battery block capacity of up to 300Ampere-hour (Ah) or more. The battery block 105 can provide varyingcapacity values. For example, the battery block 105 can provide acapacity value that corresponds to a total number of cylindrical batterycells 110 in the plurality of cylindrical battery cells 110 forming therespective battery block 105. For example, the battery block 105 canprovide a battery block capacity in a range from 8 Ah to 600 Ah.

The battery blocks 105 can have a variety of different shapes. Forexample, the shape of the battery blocks 105 can be determined orselected to accommodate a battery module 100 or battery pack withinwhich a respective battery block 105 is to be disposed. The batteryblocks 105 can have, for example, a square shape, rectangular shape,circular shape, or a triangular shape. Battery blocks 105 in a commonbattery module 100 can have the same shape or one or more battery blocks105 in a common battery module 100 can have a different shape from oneor more other battery blocks 105 in the common battery module 100.

The integrated current collector device 115 can be built or shaped toconform to (or form a part of) the shape and structure of the batteryblock 105. For example, the integrated current collector device 115 canform a top portion of the battery block 105. One or both cell holder scan be built or shaped to conform to (or form portions of) the shape andstructure of the battery block 105. For example, one of the cell holders (e.g., cell holder 225 in FIG. 2) can form a top portion of thebattery block 105, and the other cell holder (e.g., cell holder 230 inFIG. 2) can form a bottom portion of the battery block 105.

The battery module 100 can include a single battery block 105 ormultiple battery blocks 105 (e.g., two battery blocks 105, or more thantwo battery blocks 105). The number of battery blocks 105 in a batterymodule 100 can be selected based at least in part on a desired capacity,configuration or rating (e.g., voltage, current) of the battery module100 or a particular application of the battery module 100. For example,a battery module 100 can have a battery module capacity that is greaterthan the battery block capacity forming the respective battery module100. The battery module 100 can have a battery module voltage greaterthan the voltage across the battery block terminals of the battery block105 within the respective battery module 100. The battery blocks 105 canbe positioned adjacent to each other, next to each other, stacked, or incontact with each other to form the battery module 100. For example, thebattery blocks 105 can be positioned such that a side surface of thefirst battery block 105 is in contact with a side surface of the secondbattery block 105. The battery module 100 may include more than twobattery blocks 105. For example, the first battery blocks 105 can havemultiple side surfaces positioned adjacent to or in contact withmultiple side surfaces of other battery blocks 105. Various types ofconnectors can couple the battery blocks 105 together within the batterymodule 100. The connectors may include, but not limited to, straps,wires, ribbonbonds, adhesive layers, or fasteners. The electricalconnections between battery blocks 105 and battery modules 100 can usealuminum or copper busbars (stamped/cut metallic pieces in variousshapes) with fasteners, wires and ribbons (aluminum, copper, orcombination of the two), press fit studs and connectors with coppercables, or bent/formed/stamped copper or aluminum plates.

The first and second battery blocks 105 can each include an integratedcurrent collector device 115. For example, a first integrated currentcollector device 115 (e.g., multi-layered current collector) is coupledwith the first battery block 105 and a second integrated currentcollector device 115 (e.g., multi-layered current collector) is coupledwith the second battery block 105. The first and second integratedcurrent collectors 115 can include or be formed as a multi-layer currentcollector having at least one positive current collector layer (e.g.,first current collector 205 of FIG. 2), at least one negative currentcollector layer (e.g., second current collector 215 of FIG. 2), and atleast one isolation layer (e.g., isolation layer 210 of FIG. 2) disposedbetween the positive current collector layer and the negative currentcollector layer. The integrated current collector 115 can be coupledwith, disposed within, or embedded in a first cell holder. The first andsecond integrated current collector devices 115 are each coupled with aplurality of battery cells 110. For example, the first integratedcurrent collector device 115 is coupled with a first plurality ofbattery cells 110 and the second integrated current collector device 115is coupled with a second plurality of battery cells 110.

Sense lines 130 can be coupled with, disposed on, or embedded into thefirst and second integrated current collectors 115 or into the a cellholder coupled with or formed as a component of the first and secondintegrated current collectors 115. The sense lines 130 can be coupledwith, disposed on, or embedded during or after a molding procedure toform the first and second integrated current collectors 115. The senselines 130 can be coupled with a positive current collector (e.g., firstcurrent collector 205 of FIG. 2) and a negative current collector (e.g.,second current collector 215 of FIG. 2) and can be used for measuringbattery information that is being collected by a battery management unit(BMU) 140.

The BMU 140 can be coupled with the sense lines 130 through a BMU wire145. The BMU 140 can include a processor or computer module and beconfigured to measure information or data corresponding to the batterymodule 100 and the different components or layers of the first batteryblock 105 and the second battery block 105. For example, the BMU 140 canrequest, receive, or measure battery information such as but not limitedto temperate data, current sensor data, or voltage data corresponding tothe battery module 100 and the different components or layers of thefirst battery block 105 and the second battery block 105. The BMU 140can be a separate component from the battery module 100 as depicted inFIG. 1 or the BMU 140 can be formed in or embedded within the isolationlayer (e.g., isolation layer 210) of the integrated current collector115. For example, the isolation layer 210 can incorporate the BMU 140into the single structure during the injection molding. The BMU 140 caninclude or be coupled with at least one of a temperature sensor, acurrent sensor or a voltage sensor into the single structure during theinjection molding.

The sense lines 130 can include conductive material, such as but notlimited to, wires, cables, connection traces, transmission lines, bus orother forms of signal paths formed on or embedded into the first andsecond integrated current collectors 115. The sense lines 130 can beembedded into the first current collector 205 or the second currentcollector 215. For example, the sense lines 130 can be embedded into aplastic isolation portion or over-mold portion of the first currentcollector 205 or the second current collector 215. The sense lines 130can be used for monitoring data such as temperature data and voltagedata. Connections between the sense lines 130 to the first currentcollector 205 or the second current collector 215 for voltage data ortemperature data can be made through direct contact as part of theover-mold integration or other techniques such as wire bonding or laserwelding. The conductive material can include an alloy or a metal, suchas aluminum or copper.

The integrated current collector device 115 can be molded or otherwisefabricated as a single part that includes cell containment structures(e.g., first cell holder 225, second cell holder 230), currentcollectors (e.g., first current collector 205 of FIG. 2, second currentcollector 215 of FIG. 2), and can include sense lines 130. Such anintegrated current collector device 115 can be referred as an integratedcell holder. For example, during assembly, a human operator or machinecan receive an integrated cell holder and can insert the battery cellsto the single integrated cell holder to form a battery cell block (e.g.,instead of assembling the battery cells to a variety of differentcomponents to form a battery cell block). This assembly process canplace the battery cell block to be ready for welding to connect batterycell terminals to appropriate current collectors. Each of the senselines 130 can be embedded in the integrated cell holder, and can be usedto measure voltage or temperature of the battery block as a qualitycheck, during and after welding. Thus, the single, integrated currentcollector device 115 can serve multiple functions and can be assembledto battery cells within a single stage, instead of designing separateparts that attach to the battery cells at separate stages in theassembly process. This single part design can decrease part count, andcan lower PPM defect defects rate and can increase part quality.Moreover, the embedded sense lines can allow for battery monitoringduring welding and can identify issues and defect(s) at an early stageof assembly. This is in contrast with technology that solders a senseline to current collectors after welding, that would not have the samecapability to attach the associated battery block to a BMU 140 duringwelding and to identify issues at an early stage.

FIG. 2, among others, provides a partially exploded view of an examplebattery block 105 having a plurality of battery cells 110 disposedbetween a first cell holder 225 and a second cell holder 230, andillustrating the different layers or components of the integratedcurrent collector 115. For example, the integrated current collector 115includes a first current collector 205, an isolation layer 210, and asecond current collector 215. The integrated current collector 115 canbe coupled with, disposed within, or embedded in the first cell holder225.

The first cell holder 225 or the second cell holder 230 can include aplurality of layers (e.g., conductive layers, non-conductive layers)that couple the plurality of battery cells 110 with each other. Each ofthe first cell holder 225 and the second cell holder 230 can includealternating or interleaving layers of conductive layers andnon-conductive layers. For example, the second cell holder 230 mayinclude a positive conductive layer, an isolation layer having anon-conductive material, and a negative conductive layer. The firstcurrent collector 205 and the second current collector 215 can be formedfrom an electrically conductive material, and can be molded with theisolation layer 210 (e.g., electrically nonconductive material) to forma single, integrated current collector device 115 (e.g., monolithicdevice).

The first cell holder 225 and the second cell holder 230 can house,support, hold, position, or arrange the battery cells 110 to form thefirst or second battery blocks 105 and may be referred to herein asstructural layers. For example, the first cell holder 225 and the secondcell holder 230 can hold the battery cells 110 in predeterminedpositions or in a predetermined arrangement to provide the spatialseparation (e.g., spacing) described herein between each of the batterycells 110. The battery cells 110 can be evenly spaced with respect to asurface of the first cell holder 225 or the second cell holder 230. Thefirst cell holder 225 can couple with or be disposed on or over a topsurface of each of the battery cells 110. The second cell holder 230 cancouple with or contact a bottom surface of the each of the battery cells110.

The cell holder s 225, 230 can provide spatial separation betweenadjacent battery cells 110 of less than 1 mm (or less than 1.2 mm, orless than 2 mm, or other predetermined value or range). Adjacent batterycells 110 can refer to closest neighbor cell pairs. Spatial separationmay be uniform across adjacent cell pairs or may vary across certaingroups of cell pairs. The arrangement of battery cells 110 within thebattery block 105, including the spatial separation between adjacentbattery cells 110, can provide a volumetric energy density that ishigher than that of single battery cell 110 implementations. The spatialseparation between adjacent battery cells 110 can allow for suitable orsufficient thermal dissipation between battery cells 110, or avoidanceof electrical arcing between battery cells 110, and possibly otherprotective features.

The cell holder s 225, 230 can incorporate structures, such as channels150 or routing vents, to receive, direct or release high energy or highpressure gaseous release. For example, a plurality of channels 150 canbe formed in the integrated current collector device 115, the first cellholder 225, or the second cell holder 230 to vent gaseous release fromthe plurality of battery cells. The channels 150 or routing vents canreceive gaseous release through vents incorporated in the battery cells110, for instance by coupling to these vents. The cell holder s 225, 230can include material that is suitably thermally conductive, to transfer,propagate or dissipate heat resulting from the battery cells 110.

FIG. 2 includes an example view of different layers of the first cellholder 225. In particular, FIG. 2 shows a second surface (e.g., bottomsurface) of a first conductive layer 205 disposed over, coupled with, orin contact with a first surface (e.g., top surface) of a non-conductivelayer 210. A second surface (e.g., bottom surface) of the non-conductivelayer 210 is disposed over, coupled with, or in contact with a firstsurface (e.g., top surface) of a second conductive layer 215. A secondsurface (e.g., bottom surface) of the second conductive layer 215 isdisposed over, coupled with, or in contact with a first surface (e.g.,top surface) of the first cell holder 225.

In one example, the first cell holder 225 can hold, house or align thefirst conductive layer 205, the non-conductive layer 210, and the secondconductive layer 215. For example, the first cell holder 225 can includea border or raised edge formed around a border of the first cell holder225 such that the first conductive layer 205, the non-conductive layer210, and the second conductive layer 215 can be disposed within theborder or raised edge. The border or raised edge formed around a borderof the first cell holder 225 can hold the first conductive layer 205,the non-conductive layer 210, and the second conductive layer 215 inplace and in physical contact with each other. The first cell holder225, the first conductive layer 205, and the second conductive layer 215(with or without the non-conductive layer 210) can be molded orincorporated into a single part or device (e.g., integrated currentcollector device 115) using the non-conductive material. Thenon-conductive material can form the non-conductive layer 210 during themolding process. The molding process can include or use at least one ofinjection molding, block molding, compression molding, gas assistmolding, structural foam molding, thermoforming, rotational molding,film insert molding, and casting process.

The first conductive layer 205, the non-conductive layer 210, the secondconductive layer 215, the first cell holder 225, and the second cellholder 230 can include a plurality of apertures 240, 245, 250, 255, 260,respectively. The number of apertures 240, 245, 250, 255, 260 can beselected based in part on the size and dimensions of the firstconductive layer 205, the non-conductive layer 210, the secondconductive layer 215, the first cell holder 225, the second cell holder230, and the battery cells 110. For example, the first conductive layer205 can include a first plurality of apertures 240 having a first shape.The non-conductive layer 210 can include a second plurality of apertures245 having a second shape. The second conductive layer 215 can include athird plurality of apertures 250 having a third shape. The first cellholder 225 can include a fourth plurality of apertures 255 having afourth shape. The second cell holder 230 can include a fourth pluralityof apertures 260 having a fifth shape. The apertures 240, 245, 250, 255,260 can include an opening or hole formed through each of the respectivelayers, or a recess formed into the respective layers or structures. Theapertures 240, 245, 250, 255, 260 can be aligned with respect to eachother (or with a battery cell) within a battery block 105. One or moreof the apertures 240, 245, 250, 255 can extend through multiple layers(e.g., through the first conductive layer 205, the non-conductive layer210, the second conductive layer 215, and the first cell holder 225).For example, the apertures 240, 245, 250, 255 can collectively form anextended aperture from a top surface to a bottom surface of theintegrated current collector device 115 for instance. Two or more of theapertures 240, 245, 250, 255 can be maintained, aligned, connected,extended, implemented or formed as an extended aperture during themolding process (e.g., using alignment structures or casts). Part of thenonconductive material used in the molding process can be used to formone or more portions of the extended aperture (e.g., at a top surfaceand a bottom surface of the integrated current collector device 115).

The shape, dimensions, or geometry of one or more of the first pluralityof apertures 240, the second plurality of apertures 245, the thirdplurality of apertures 250, the fourth plurality of apertures 255, andthe fifth plurality of apertures 260 can be different. The shape,dimensions, or geometry of one or more of the first plurality ofapertures 240, the second plurality of apertures 245, the thirdplurality of apertures 250, the fourth plurality of apertures 255, andthe fifth plurality of apertures 260 can be the same or substantiallysimilar. Two or more of the first, second, third, fourth and fifthshapes can be conformed at least in part relative to one other. Two ormore of the first, second, third, fourth and fifth pluralities ofapertures can be aligned relative to one other. The shape, dimensions,or geometry of the apertures 240, 245, 250, 255, 260 can be determinedbased at least in part on the shape, dimensions, or geometry of thebattery cells 110. For example, the plurality of battery cells 110 canbe disposed or positioned between a second surface (e.g., bottomsurface) of the first cell holder 225 and a first surface (e.g., topsurface) of the second cell holder 230. The first cell holder 225 or thesecond cell holder 230 can hold, house or align the plurality of batterycells 110 using the fourth plurality of apertures 255 or the fifthplurality of apertures 260, respectively. For example, each of thebattery cells 110 can be disposed within the battery block 105 such thata bottom end or bottom portion of a battery cell 110 is disposed in,coupled with or on contact with at least one aperture of the fifthplurality of apertures 260 formed in the second cell holder 230, and atop end or top portion of a battery cell 110 is disposed in, coupledwith or on contact with at least one aperture of the fourth plurality ofapertures 255 formed in the first cell holder 225.

The apertures 240, 245, 250 of the first conductive layer 205, thenon-conductive layer 210, and the second conductive layer 215 (as partof the integrated current collector device 115) can allow a connectionto a positive layer (e.g., first conductive layer 205) or negative layer(e.g., second conductive layer 215) from each of the battery cells 110.For example, a wirebond (e.g., wirebond 305 of FIG. 3) can extendthrough the apertures 240, 245, 250 to couple a positive terminal orsurface of a battery cell 110 with the first conductive layer 205. Thus,the apertures 240, 245, 255 can be sized to have a diameter or openingthat is greater than a diameter or cross-sectional shape of the wirebond305. A negative tab (e.g., negative tab 310 of FIG. 3) can extend fromthe second conductive layer 215 and be connected to negative surfaces orterminals on at least two battery cells 110. Thus, the apertures 240,245, 250 can be sized to have dimensions that are greater than thedimensions of the negative tab 310, or greater than a diameter orcross-sectional shape of the wirebond. For example, a wirebond canextend from the negative tab to couple with a portion of a negativeterminal on a battery cell 110 that is exposed by the aperture 250.Thus, one or more of the apertures 240, 245, 250 can be sized to havedimensions that are greater than the dimensions of the negative tab, orgreater than a diameter or cross-sectional shape of the wirebond. Theshape of the apertures 240, 245, 250, 255, 260 can include a round,rectangular, square, or octagon shape or form as some examples. Thedimensions of the apertures 240, 245, 250, 255, 260 can include a widthof 21 mm or less for instance. The dimensions of one or more of theapertures 240, 245, 250, 255, 260 can be 12 mm in width and 30 mm inlength for example.

The apertures 240, 245, 250 can be formed such that they are smallerthan the apertures 255, 260. For example, the apertures 255 and 260 canhave a diameter in a range from 10 mm to 35 mm (e.g., 18 mm to 22 mm).The apertures 240, 245, 250 can have a diameter in a range from 3 mm to33 mm. If the apertures 255, 260 are formed having a square orrectangular shape, the apertures 255, 260 can have a length in a rangefrom 4 mm to 25 mm (e.g., 10 mm). If the apertures 255, 260 are formedhaving a square or rectangular shape, the apertures 255, 260 can have awidth in a range from 4 mm to 25 mm (e.g., 10 mm). For example, theapertures 255, 260 can have dimensions of 10 mm×10 mm. If the apertures240, 245, 250 are formed having a square or rectangular shape, theapertures 240, 245, 250 can have a length in a range from 2 mm to 20 mm(e.g., 7 mm). If the apertures 240, 245, 250 are formed having a squareor rectangular shape, the apertures 240, 245, 250 can have a width in arange from 2 mm to 20 mm (e.g., 7 mm). For example, the apertures 240,245, 250 can have dimensions of 7 mm×7 mm.

Apertures 245 can be formed such that they are smaller (e.g., havesmaller dimensions) or offset with respect to apertures 240. Forexample, apertures 245 can correspond to apertures 240, such as havingthe same geometric shape with just an offset to make the apertures 245smaller with respect to apertures 240. For example, the offset can be ina range from 0.1 mm to 6 mm depending on isolation, creepage, andclearance requirements. Apertures 245 can be sized the same as oridentical to aperture 240.

The apertures 240, 245, 250 can be formed in a variety of shapes. Forexample, the apertures 240, 245, 250 may not be formed as distinctpatterned openings or formed having distinct patterned openings. Forexample, the apertures 240, 245, 250 can be formed as a geometric cutfrom the sides of the respective one of layers 205, 210, 215. Theapertures 240, 245, 250 can be formed as half circular cutouts aroundthe perimeter of each of the respective one of layers 205, 210, 215,respectively.

The first conductive layer 205 and the second conductive layer 215 caninclude an electrically conductive material, a metal (e.g., copper,aluminum), or a metallic material. The first conductive layer 205 can bea positive conductive layer or positively charged layer. The secondconductive layer 215 can be a negative conductive layer or negativelycharged layer. The first conductive layer 205 and the second conductivelayer 215 can have a thickness in a range of 0.1 to 8 millimeters (e.g.,1.5 mm). For example, the first current collector 205 or the secondcurrent collector 215 can include or be made of a thin conductive metal(e.g., of less than 5 millimeter in thickness, although other dimensionsare contemplated) or metal layer. The first conductive layer 205 and thesecond conductive layer 215 can have the same length as battery block105. The first conductive layer 205 and the second conductive layer 215can have the same width as battery block 105.

The first current collector 205 can be made of a metal such as copper oraluminum, and can be affixed or mounted (e.g., directly) on a batterycell. The first current collector 205 can be designed or implementedwith precise cut-outs or apertures 240 whereby a positive terminalconnection can be made by welding from the positive wirebond to thefirst current collector 205 (e.g., a top surface portion of the firstcurrent collector 205, or an edge surface portion of a correspondingaperture 240). The first current collector 205 can be designed orimplemented with partial cut-outs or partially-formed apertures 240 ator along one or more edges of the layer, to expose at least one positiveterminal of the battery cells 110 through the layer. The second currentcollector 215 can be designed or implemented with precise cut-outs orapertures 250 where a wirebond head can touch the rim of the batterycell 110 and bond to the second current collector 215. The secondcurrent collector 215 can be designed or implemented with partialcut-outs or partially-formed apertures 250 at or along one or more edgesof the layer, to expose at least one positive terminal of the batterycells 110 through the layer. The second current collector 215 can bedesigned or implemented to support resistive welding for instance, inwhich a bondhead can contact the second current collector 215 directlyand weld to the rim to make a negative terminal connection.

A portion of the isolation layer 210 can be disposed or located abovethe second current collector 215 to provide isolation from the firstcurrent collector 205. The isolation layer 210 (or non-conductive layer)can include insulation material, plastic material, epoxy material, FR-4material, polypropylene materials, or formex materials. The dimensionsor geometry of the non-conductive layer 210 can be selected to provide apredetermined creepage, clearance or spacing (sometimes referred to ascreepage-clearance specification or requirement) between the firstconductive layer 205 and the second conductive layer 215. For example, athickness or width of the non-conductive layer 210 can be selected suchthat the first conductive layer 205 is spaced at least 3 mm from thesecond conductive layer 215 when the non-conductive layer 210 isdisposed between the first conductive layer 205 and the secondconductive layer 215. The non-conductive layer 210 can be formed havinga shape or geometry that provides the predetermined creepage, clearanceor spacing. For example, the non-conductive layer 210 can have adifferent dimension than that the first conductive layer 205 and thesecond conductive layer 215, such that an end or edge portion of thenon-conductive layer 210 extends out farther (e.g., longer) than an endor edge portion of the first conductive layer 205 and the secondconductive layer 215 relative to a horizontal plane or a vertical plane.The distance that an end or edge portion of the non-conductive layer 210extends out can provide the predetermined creepage, clearance or spacing(e.g., 3 mm creepage or clearance). The thickness and insulatingstructure of the non-conductive layer 210, that separate the firstconductive layer 205 from the second conductive layer 215, can providethe predetermined creepage, clearance or spacing. Thus, the dimensionsof the non-conductive layer 210 can be selected, based in part, to meetcreepage-clearance specifications or requirements. The dimensions of thenon-conductive layer 210 can reduce or eliminate arcing between thefirst conductive layer 205 and the second conductive layer 215. Thenon-conductive layer 210 can have a thickness that ranges from 0.1 mm to8 mm (e.g., 1 mm). The non-conductive layer 210 can have the same widthas the battery block 105. For example, the non-conductive layer 210 canhave a width in a range from 25 mm to 700 mm (e.g., 330 mm). Thenon-conductive layer 210 can have the same length as the battery block105. For example, the non-conductive layer 210 can have a length in arange from 25 mm to 700 mm (e.g., 150 mm).

The material and structural configuration of the cell holders 225, 230can provide spatial separation between cells such that creepage orclearance (creepage-clearance) requirements are met or exceeded forsupporting a certain voltage across terminals of a battery pack 440(e.g., 400 V, or 450 V) or of a battery module 100 (e.g., 60 V) that isimplemented using the battery blocks 105. Creepage can refer to aseparation (e.g., shortest distance) between connection or weld pointsbetween (e.g., like-terminals of) battery cells 110 as measured along asurface of a bus-bar, circuit board or other connecting structure.Clearance can refer to a separation (e.g., shortest distance) betweenconnection or weld points between (e.g., like-terminals of) batterycells 110 as measured through air or space.

The first cell holder 225, the second cell holder 230 and thenon-conductive layer 210 can include or be molded from an electricallynonconductive, flame retardant material, for example to provide rigidopen slots to hold the battery cells 110. The first cell holder 225 andthe second cell holder 230 can have a flame resistance rating (e.g., FRrating) of UL 94 rating of V-0 or greater. For example, the first holder225 or the second cell holder 230 can have a UL 94 (e.g., plasticsflammability of plastic materials) rating of V-0 that corresponds to athickness of a wall portion of the respective layer. The thinner a wallthickness is the more difficult it can be to achieve a V-0 rating. Thus,the first cell holder 225 or the second cell holder 230 can have athickness between 0.5 mm to 2.5 mm. The first cell holder 225 and thesecond cell holder 230 can include plastic material, acrylonitrilebutadiene styrene (ABS) material, polycarbonate material, or nylonmaterial (e.g., PA66 nylon) with glass fill for instance. The rigidityof first cell holder 225 and the second cell holder 230 can correspondto the material properties forming the respective first cell holder 225and the second cell holder 230, such as flexural modulus.

The non-conductive layer 210 can include an isolation material ornonconductive material having high dielectric strength that can provideelectrical isolation. The isolation material can have a dielectricstrength ranging from 250V/mil to 350V/mil. For example, the isolationmaterial or nonconductive material can have a dielectric strength of300V/mil (other values or ranges of the values are possible).

The non-conductive material can hold the first current collector 205 andthe second current collector 215 together or in place. The nonconductivematerial can have a tensile strength ranging from 8,000 psi to 10,000psi. For example, the first cell holder 225 and the second cell holder230 can have a tensile strength of 9,000 psi (other values or ranges ofthe values are possible). The nonconductive material can have a flexuralmodulus (e.g., stiffness/flexibility) ranging from 350,000 psi to450,000 psi. For example, the first cell holder 225 and the second cellholder 230 can have a flexural modulus (e.g., stiffness/flexibility) of400,000 psi (other values or ranges of the values are possible). Thevalues for the dielectric strength, tensile strength, or flexuralmodulus can vary outside these values or range of values and can beselected based in part on a particular application or specification ofthe first cell holder 225 and the second cell holder 230 for instance.

The non-conductive layer 210 can provide or include a conformal coatingor lamination layer that protects against shorting from the firstcurrent collector 205 and the second current collector 215 (e.g., thepositive and negative current collectors), and can expose weld areas(e.g., for welding to battery cell terminals). This design can supportdifferent weld techniques, such as wire bonding or laser welding (e.g.,for the negative connections).

For example, using the single sided weld approach discussed herein, thepositive and negative terminal connections to the first currentcollector 205 and the second current collector 215, respectively, can bemade from the same end of the battery cell 110 at which the rim 220(e.g., top cap) is located. The rim 220, edge or other portion of thetop cap assembly can form or provide a negative terminal and can bewelded to a current collector for negative collections. Welding can beperformed to for example a narrow and non-flat (protruded) profile ofthe rim 220 at the top cap (e.g., along the round edge that extends intothe cylindrical surface of the battery cell), to connect the negativeterminal to a portion of a current collector for negative collections.For example, welding can be performed to connect the negative terminalto an aperture edge (e.g., of a tabbed or protruded portion of theaperture), or an upper surface portion (e.g., of a tabbed or protrudedportion of the aperture) of the current collector (e.g., negativecurrent collector) for negative collections. The positive terminal tabportion of the top cap can be connected to a portion of a currentcollector (e.g., first current collector) for positive collections. Forexample, welding can be performed to an aperture edge or top surfaceportion of the current collector for positive collections. Hence, inaccordance with the concepts disclosed herein, a current collectorconfiguration is provided that can support positive and negative weldconnections at the top cap end, that can support one or more methods forwelding, that can support tool access (e.g., for welding, assembly), andthat can provide isolation between the negative and positive currentcollectors.

The term weld is sometimes used herein by way of illustration (e.g., inresistive/laser welding or electrically connecting a current collectorto a terminal), and is not intended to be limiting in any way to aspecific manner of connection. As disclosed herein, the term weld issometimes used interchangeably with connect or bond (e.g., wirebond305). For example, the wirebond 305 can include a first end that iswelded, connected, or bonded with a surface of a battery cell 110 and asecond end that is welded, connected, or bonded with a conductivepositive layer 205. The negative tab 310 can include a first end that iswelded, connected, or bonded with a surface of at least two batterycells 110 and a second end that is welded, connected, or bonded with aconductive negative layer 215.

Each of the plurality of battery cells 110 can be cylindrical in shapeor structure. The battery cell 110 can have a top cap or rim 220. Therim 220 can include, incorporate or hold a tab or conductive structurelocated within or at a center of the top cap that forms a positiveelectrical terminal of the battery cell 110. The battery cell 110 can beformed from a metallic or conductive housing. The housing or outersurface may operate as the main casing for the battery cell 110. The canmay comprise a surface structure that forms a negative electricalterminal of the battery cell 110. FIG. 2 shows multiple ones of anexample embodiment of a cylindrical battery cell 110. Depending on theshape of each battery cell 110, the battery cells 110 can be arrangedspatially relative to one another to reduce overall volume of thebattery block 105, to allow for minimum cell to cell spacing (e.g.,without failure or degradation in performance), or to allow for anadequate number of vent ports. For instance, the rows of battery cells110 can be arranged in a slanted or offset formation relative to oneanother. The battery cells 110 can be placed in various other formationsor arrangements.

FIG. 3, among others, depicts a top view of the battery module 100illustrating an example arrangement of the battery cells 110 in each ofthe first battery block 105 and the second battery block 105. Thebattery blocks 105 can include a pair of terminals 330, 335. Forexample, the battery blocks 105 include a first battery block terminal330 and a second battery block terminal 335. The first battery blockterminal 330 can correspond to a positive terminal and the secondbattery block terminal 335 can correspond to a negative terminal Theplurality of cylindrical battery cells 110 can provide a battery blockcapacity to store energy that is at least five times greater than abattery cell capacity of each of the plurality of cylindrical batterycells 110. The battery blocks 105 can have a voltage of up to 5 voltsacross the pair of battery block terminals 330, 335. For example, thefirst battery block terminal 330 can be coupled with 5 V and the secondbattery block terminal 335 can be coupled with 0 v. The first batteryblock terminal 330 can be coupled with +2.5 V and the second batteryblock terminal 335 can be coupled with −2.5 V. Thus, a difference involtage between the first battery block terminal 330 and the secondbattery block terminal 335 can be 5 V or up to 5 V.

The battery cells 110 in the first and second battery blocks 105 can bearranged in one or more rows and one or more columns of battery cells110. The individual battery cells 110 can be cylindrical cells or othertypes of cells. Depending on the shape of each battery cell 110, thebattery cells 110 can be arranged spatially relative to one another toreduce overall volume of the battery block 105, to minimize cell to cellspacing (e.g., without failure or degradation in performance), or toallow for an adequate number of vent ports. For instance, FIG. 3, amongothers, shows each row of battery cells 110 arranged in a slanted oroffset formation relative to one another. The battery cells 110 can beplaced in various other formations or arrangements.

The battery cells 110 in a common battery block 105 can be uniformlyspaced, evenly spaced or one or more battery cells 110 in a commonbattery block 105 can be spaced one or more different distances fromanother one or more battery cells 110 of the common battery block 105.Each of the battery cells 110 in a common battery block 105 (e.g., samebattery block 105) can be spaced from a neighboring or adjacent batterycell 110 in all directions by a distance that ranges from 0.5 mm to 3 mm(e.g., 1.5 mm spacing between each battery cell 110, 2 mm spacingbetween each battery cell 110). For example, a first battery cell 110can be spaced a distance of 1.5 mm from a neighboring second batterycell 110 and spaced a distance of 1.5 mm from a neighboring thirdbattery cell 110. The battery cells 110 in a common battery block 105can be uniformly spaced, or evenly spaced. One or more battery cells 110in a common battery block 105 can be spaced one or more differentdistances from another one or more battery cells 110 of the commonbattery block 105. Depending on the shape of each battery cell 110, thebattery cells 110 can be arranged spatially relative to one another toreduce overall volume of the battery block 105, to allow for minimumcell to cell spacing (e.g., without failure or degradation inperformance), or to allow for an adequate number of vent ports. Forinstance, each row of battery cells 110 can be arranged in a slanted oroffset formation relative to one another. The battery cells 110 can beplaced in various other formations or arrangements.

The battery cells 110 (e.g., adjacent battery cells 110) betweendifferent battery blocks 105 (e.g., adjacent battery blocks 105) can bespaced a distance in a range from 2 mm to 6 mm. For example, one or morebattery cells 110 disposed along an edge of a first battery block 105can be spaced a distance in a range from 0 mm to 1 mm (e.g., 0.5 mm)from the edge of the first battery block 105 and one or more batterycells 110 disposed along an edge of a second battery block 105 can bespaced a distance in a range from 0 mm to 1 mm (e.g., 0.5 mm) from theedge of the second battery block 105. The edges of the first and secondbattery blocks 105 can be coupled with each other, in contact with eachother, or facing each other such that the one or more battery cells 110disposed along the edge of the first battery block 105 are spaced fromthe one or more battery cells 110 disposed along the edge of the secondbattery block 105 a distance in a range from 2 mm to 6 mm (e.g., 4.5mm). The distances between the battery cells 110 of different batteryblocks 105 can vary and can be selected based at least in part on thedimensions of the battery blocks 105, electrical clearance or creepagespecifications, or manufacturing tolerances for the respective batterymodule 100. For example, battery cells 110 can be spaced a distance froma second, different battery cell 110 based on predeterminedmanufacturing tolerances that may control or restrict how close batterycells 110 can be positioned with respect to each other.

The battery cells 110 can each couple with a first layer 205 (e.g.,positive conductive layer) of the first cell holder 225. For example,the first cell holder 225 can include multiple layers, such as, a firstlayer forming a positive current collector 205, an isolation layer 210having non-conductive material, and a second layer forming negativecurrent collector 215. Each of the battery cells 110 can include a pairof battery cell terminals 320, 325. For example, the battery cells 110can include a positive terminal 320 and a negative terminal 325. Thepair of terminals 320, 325 of each of the battery cells 110 can have upto 5 V across their respective terminals. For example, the positiveterminal 320 can be coupled with +5 V and the negative terminal 325 canbe coupled with 0 V. The positive terminal 320 can be coupled with +2.5V and the negative terminal 325 can be coupled with −2.5 V. Thus, thedifference in voltage between the positive terminal 320 and the negativeterminal 325 of each battery cell 110 can be 5 V or in any value up toand including 5 V.

The positive terminal 320 of a battery cell 110 can be connected using awirebond 305 or otherwise, with the first layer 205 of the first cellholder 225. The negative terminal 325 or negative surface of a batterycell 110 can connect with the second layer 215 of the first cell holder225 through a negative tab 310. The positive terminal 320 and thenegative terminal 325 of a battery cell 110 can be formed on or coupledwith at least a portion of the same surface (or end) of the respectivebattery cell 110. For example, the positive terminal 320 can be formedon or coupled with a first surface (e.g., top surface, side surface,bottom surface) of the battery cell 110 and the negative terminal 325 ofthe battery cell 110 can be formed on or coupled with the same firstsurface. Thus, the connections to positive and negative bus-bars orcurrent collectors can be made from the same surface (or end) of thebattery cell 110 to simplify the installation and connection of thebattery cell 110 within a battery block 105.

The negative tab 310 can couple at least two battery cells 110 with aconductive negative layer 215 of the first cell holder 225. The negativetab 310 can be part of the conductive negative layer 215, for exampleformed as an extension or structural feature within a plane of theconductive negative layer 215, or partially extending beyond the plane.The negative tab 310 can include conductive material, such as but notlimited to, metal (e.g., copper, aluminum), or a metallic alloy ormaterial. The negative tab 310 can form or provide a contact point tocouple a battery cell 110 to a negative current collector 215 of thefirst cell holder 225. The negative tab 310 can couple with or contact atop portion or top surface (e.g., negative terminal 325) of the batterycell 110. The negative tab 310 can couple with or contact a side surfaceof a battery cell 110. The negative tab 310 can couple with or contact abottom portion or bottom surface of a battery cell 110. The surface orportion of a battery cell 110 the negative tab 310 couples with orcontacts can correspond to the placement of the first cell holder 225relative to the battery cell 110.

The negative tab 310 can have a shape configured to couple with orcontact surfaces of at least two battery cells 110. The negative tab 310can be formed in a variety of different shapes and have a variety ofdifferent dimensions (e.g., conformed to the dimensions of the batterycells 110 and their relative positions). The shape of the negative tab310 can include, but not limited to, rectangular, square, triangular,octagon, circular shape or form, or one or more combinations ofrectangular, square, triangular, or circular shape or form. For example,the negative tab 310 can be formed having one or more sides (e.g.,portions or edges) having a circular or curved shape or form to contacta surface of the battery cells and one or more sides having a straightor angled shape. The particular shape, form or dimensions of thenegative tab 310 can be selected based at least in part on a shape, formor dimensions of the battery cells 110 or a shape, form or dimensions ofthe first cell holder 225. The shape and structure of the negative tab310 can be formed in two or three dimensions. For example, one or moreedges or portions of the negative tab 310 can be folded or formed into ashape or structure suitable for bonding to a negative terminal portionof a battery cell 110. For a two-dimensional negative tab 310 (e.g., anegative tab 310 with a thickness conformed with a thickness of thecorresponding conductive negative layer), the negative tab 310 caninclude or be described with one or more parameters, such as length, awidth, surface area, and radius of curvature. For a three-dimensionalnegative tab 310 (e.g., a negative tab 310 with at least a portion thatdoes not conform with a thickness of the corresponding conductivenegative layer), the negative tab 310 can include or be described withone or more parameters, including length, width, height (or depth,thickness), one or more surface areas, volume, and radius of curvature.The three-dimensional negative tab 310 can include a folded, curved oraccentuated portion that provides a larger surface for a negativesurface of a battery cell 110 to couple with or contact. For example,the three-dimensional negative tab 310 can have a greater thickness thana two-dimensional negative tab 310.

The wirebond 305 can be a positive wirebond 305 that can couple at leastone battery cell 110 with a conductive positive layer 205 of the cellholder 225. The wirebond 305 can be formed in a variety of differentshapes and have a variety of different dimensions. The particular shapeor dimensions of wirebond 305 can be selected based at least in part ona shape or a dimension of the battery cells 110 or a shape or adimension of the first cell holder 225. For example, the wirebond 305can be sized to extend from a top surface, side surface or bottomsurface of a battery cell 110. As depicted in FIG. 3, the wirebond 305can extend from a top surface (e.g., a positive terminal 320) of abattery cell 110 and extend through apertures 240, 245, 250 formed ineach of the different layers forming the first cell holder 225, tocontact a top surface of the conductive positive layer 205 of the cellholder 225. The shape of the wirebond 305 can be selected or implementedso as not to contact a negative layer of the first cell holder 225 asthe wirebond 305 extends through the different layers forming the firstcell holder 225. The shape or form of the wirebond 305 can include arectangular shape, cylindrical shape, tubular shape, spherical shape,ribbon or tape shape, curved shape, flexible or winding shape, orelongated shape. The wirebond 305 can include electrical conductivematerial, such as but not limited to, copper, aluminum, metal, ormetallic alloy or material.

FIG. 4 depicts a cross-section view 400 of an electric vehicle 405installed with a battery pack 440. The battery pack 440 can include aplurality of battery modules 100. The plurality of battery modules 100can include a plurality of battery blocks 105. The battery blocks 105can include a plurality of cylindrical battery cells 110. Each of theplurality of cylindrical battery cells 110 can include a positiveterminal 320 and a negative terminal 325 coupled with an integratedcurrent collector device 115. The battery pack 440 can reside or bedisposed within the electric vehicle 405. The electric vehicle 405 caninclude an autonomous, semi-autonomous, or non-autonomous human operatedvehicle. The electric vehicle 405 can include a hybrid vehicle thatoperates from on-board electric sources and from gasoline or other powersources. The electric vehicle 405 can include automobiles, cars, trucks,passenger vehicles, industrial vehicles, motorcycles, and othertransport vehicles. The electric vehicle 405 can include a chassis 410(sometimes referred to herein as a frame, internal frame, or supportstructure). The chassis 410 can support various components of theelectric vehicle 405. The chassis 410 can span a front portion 415(sometimes referred to herein a hood or bonnet portion), a body portion420, and a rear portion 425 (sometimes referred to herein as a trunkportion) of the electric vehicle 405. The front portion 415 can includethe portion of the electric vehicle 405 from the front bumper to thefront wheel well of the electric vehicle 405. The body portion 420 caninclude the portion of the electric vehicle 405 from the front wheelwell to the back wheel well of the electric vehicle 405. The rearportion 425 can include the portion of the electric vehicle 405 from theback wheel well to the back bumper of the electric vehicle 405.

The battery pack 440 that includes cylindrical battery cells 110 coupledwith an integrated current collector device 115 can be installed orplaced within the electric vehicle 405. For example, the battery pack440 can couple with a drive train unit of the electric vehicle 405. Thedrive train unit may include components of the electric vehicle 405 thatgenerate or provide power to drive the wheels or move the electricvehicle 405. The drive train unit can be a component of an electricvehicle drive system. The electric vehicle drive system can transmit orprovide power to different components of the electric vehicle 405. Forexample, the electric vehicle drive train system can transmit power fromthe battery pack 440 to an axle or wheels of the electric vehicle 405.The battery pack 440 can be installed on the chassis 410 of the electricvehicle 405 within the front portion 415, the body portion 420 (asdepicted in FIG. 4), or the rear portion 425. A first bus-bar 435 and asecond bus-bar 430 can be connected or otherwise be electrically coupledwith other electrical components of the electric vehicle 405 to provideelectrical power from the battery pack 440 to the other electricalcomponents of the electric vehicle 405.

The battery pack 440 can include a battery system having multiplebattery modules 100 (e.g., two or more). Multiple battery modules 100can be electrically coupled with each other to form a battery pack 440,using one or more electrical connectors such as bus-bars. For example,battery blocks 105 can be electrically coupled or connected to one ormore other battery blocks 105 to form a battery module 100 or batterypack 440 of a specified capacity and voltage. The number of batteryblocks 105 in a single battery module 100 can vary and can be selectedbased at least in part on a desired capacity of the respective batterymodule 100. The number of battery modules 100 in a single battery pack440 can vary and can be selected based at least in part on a desiredcapacity of the respective battery pack 440. For example, the number ofbattery modules 100 in a battery pack 440 can vary and can be selectedbased at least in part on an amount of energy to be provided to anelectric vehicle. The battery pack 440 can couple or connect with one ormore bus-bars of a drive train system of an electric vehicle to provideelectrical power to other electrical components of the electric vehicle(e.g., as depicted in FIG. 4).

The battery blocks 105 and the battery modules 100 can be combinablewith one or more other battery blocks 105 and battery modules 100 toform the battery pack 440 of a specified capacity and a specifiedvoltage that is greater than that across the terminals of the batteryblock 105 or battery module 100. For instance, a high-torque motor maybe suitably powered by a battery pack 440 formed with multiple batterycells 110 (e.g., 500 cells), blocks 105 or modules 100 connected inparallel to increase capacity and to increase current values (e.g., inAmperes or amps) that can be discharged. A battery block 105 can beformed with 20 to 50 battery cells 110 for instance, and can provide acorresponding number of times the capacity of a single battery cell 110.A battery pack 440 formed using at least some battery blocks 105 orbattery modules 100 connected in parallel can provide a voltage that isgreater than that across the terminals of each battery block 105 orbattery module 100. A battery pack 440 can include any number of batterycells 110 by including various configurations of battery blocks 105 andbattery modules 100.

The battery module 100 or battery pack 440 having one or more batteryblocks 105 can provide flexibility in the design of the battery module100 or the battery pack 440 with initially unknown space constraints andchanging performance targets. For example, standardizing and using smallbattery blocks 105 can decrease the number of parts (e.g., as comparedwith using individual cells) which can decrease costs for manufacturingand assembly. The battery modules 100 or battery packs 440 having one ormore battery blocks 105 as disclosed herein can provide a physicallysmaller, modular, stable, high capacity or high power device that is notavailable in today's market, and can be an ideal power source that canbe packaged into various applications.

The shape and dimensions of the battery pack 440 can be selected toaccommodate installation within an electric vehicle 405. For example,the battery pack 440 can be shaped and sized to couple with one or morebus-bars 430, 435 of a drive train system (which includes at least partof an electrical system) of an electric vehicle 405. The battery pack440 can have a rectangular shape, square shape, or a circular shape,among other possible shapes or forms. The battery pack 440 (e.g., anenclosure or outer casing of the battery pack 440) can shaped to hold orposition the battery modules 100 within a drive train system of anelectric vehicle 405. For example, the battery pack 440 can be formedhaving a tray like shape and can include a raised edge or border region.Multiple battery modules 100 can be disposed within the battery pack 440can be held in position by the raised edge or border region of thebattery pack 440. The battery pack 440 may couple with or contact abottom surface or a top surface of the battery modules 100. The batterypack 440 can include a plurality of connectors to couple the batterymodules 100 together within the battery pack 440. The connections mayinclude, but not limited to, straps, wires, adhesive materials, orfasteners.

The battery blocks 105 can be coupled with each other to form a batterymodule 100 and multiple battery modules 100 can be coupled with eachother to form a battery pack 440. The number of battery blocks 105 in asingle battery module 100 can vary and be selected based at least inpart on a desired capacity or voltage of the respective battery module100. The number of battery modules 100 in a single battery pack 440 canvary and be selected based at least in part on a desired capacity of therespective battery pack 440. For instance, a high-torque motor may besuitably powered by a battery pack 440 having multiple battery modules100, the battery modules 100 having multiple battery blocks 105 and thebattery blocks 105 having multiple battery cells 110. Thus, a batterypack 440 can be formed with a total number of battery cells 110 rangingfrom 400 to 600 (e.g., 500 battery cells 110), with the battery blocks105 or battery modules 100 connected in parallel to increase capacityand to increase current values (e.g., in Amperes or amps) that can bedischarged. A battery block 105 can be formed with any number of batterycells 110 and can provide a corresponding number of times the capacityof a single battery cell 110.

FIG. 5, among others, depicts an example embodiment of a method 500 ofproviding a system to power electric vehicles 405. The method 500 caninclude providing a battery pack 440 (ACT 505). The battery pack 440 canbe disposed within an electric vehicle 405. The battery pack 440 can beformed having multiple battery modules 100. For example, two or morebattery modules 100 can be electrically coupled together to form abattery pack 440. The battery module 100 can be formed by electricallycoupling two or more battery blocks 105 together. For example, batteryblock terminals 330, 335 can electrically couple a first battery block105 with a second battery block 105 to form at least one battery module100. The battery blocks 105 can be electrically coupled in series. Thebattery blocks 105 can be electrically coupled in parallel.

The method 500 can include disposing a plurality of cylindrical batterycells 110 in a battery block 105 (ACT 510). For example, multiple (e.g.,two or more) battery cells 110 can be disposed within at least onebattery block 105. The battery cells 110 can be disposed such that theyare uniformly spaced, evenly spaced within a common battery block 105 orthe battery cells 110 can be disposed such that they are spaced one ormore different distances from another one or more battery cells 110 ofthe common battery block 105. For example, the battery cells 110 can bespaced from a neighboring or adjacent battery cell 110 in all directionsby a distance that ranges from 0.5 mm to 3 mm (e.g., 1.5 mm spacingbetween each battery cell 110, 2 mm spacing between each battery cell110). Battery cells 110 in a common battery block 105 can be spaced oneor more different distances from another one or more battery cells 110of the common battery block 105. Depending on the shape of each batterycell 110, the battery cells 110 can be arranged spatially relative toone another to reduce overall volume of the battery block 105, to allowfor minimum cell to cell spacing (e.g., without failure or degradationin performance), or to allow for an adequate number of vent ports. Rowsof battery cells can be arranged in a slanted or offset formationrelative to one another. The battery cells 110 can be placed in variousother formations or arrangements.

The method 500 can include forming an integrated current collectordevice 115 (ACT 515). For example, an integrated current collectordevice 115 can be formed via injection molding using an isolation layer210 (e.g., nonconductive material), by incorporating a first currentcollector 205 and a second current collector 215 into the integratedcurrent collector device 115 during the injection molding. The isolationlayer 210 can bind or otherwise couple the first current collector 205with the second current collector 215. For example, the isolation layer210 can include or be coated with an adhesive material to couple withthe first current collector 205 on a first surface and couple with thesecond current collector 215 on a second surface. The integrated currentcollector device 115 can be formed using various techniques, such as amolding process. The molding process can include or use at least one ofinjection molding, block molding, compression molding, gas assistmolding, structural foam molding, thermoforming, rotational molding,film insert molding, and casting process. For example, the integratedcurrent collector device 115 can be formed via molding using theisolation layer 210, by incorporating a first current collector 205, asecond current collector 215, and one or more sense lines 130 into theintegrated current collector device 115 during the molding, andproviding electrical isolation between the first current collector 205and the second current collector 215. For example, the isolation layer210 can be disposed on or over a top surface of the second currentcollector 215 using various techniques, including but not limited to,injection molding. A first cell holder 225 can be used a mold and holdthe second current collector 215 while the material of the isolationlayer 210 is disposed on or over a top surface of the second currentcollector 215. For example, the material of the isolation layer 210 canbe provided to or fed into the mold such that the material of theisolation layer 210 forms over a top surface of the second currentcollector 215. The isolation layer 210 can include a nonconductivematerial. The mold can include barriers or cutouts regions thatcorrespond to the apertures 240, 245, 255 of the first current collector205, the isolation layer 210, and second current collector 215,respectively. For example, during the molding process, the materials ofthe different layers can be provided to or fed into the respective moldsand the barriers can prevent the material from forming in regionsintended to be apertures for the respective regions. Thus, each of thefirst current collector 205, the isolation layer 210, and second currentcollector 215 can be formed having apertures 240, 245, 250,respectively.

During an injection molding process, the first current collector 215 andthe second current collector 215 can be integrated first. For example,the first current collector 205 and the second current collector 215 canbe individually overmolded to isolate their respective edges and atleast one surface of the first current collector 205 or the secondcurrent collector 215. In a separate injection molding step, the firstcurrent collector 205 and the second current collector 215 can beovermolded into a single assembly in which one or more surface areas ofthe first current collector 205 and the second current collector 215 canbe isolated in plastic or plastic material except the critical weldingareas or surfaces of the first current collector 205 or the secondcurrent collector 215. The single assembly including the first currentcollector 205 and the second current collector 215 can be joined withthe first cell holder 225 or the second cell holder 230 to complete theintegration. The single assembly including the first current collector205 and the second current collector 215 can be joined with the firstcell holder 225 or the second cell holder 230 using, but not limited to,ultrasonic welding, laser welding, adhesive tape, or liquid adhesive.The entire assembly of the battery block 105 can be integrated as asingle assembly. For example, instead of an isolation layer 210, thefirst current collector 205 and the second current collector 215 can beseparated as part of the injection molding process by filling the spacepreviously occupied by the isolation layer 210 with a plastic materialor molten plastic. An injection mold tool used during the injectionmolding process can include two or more sections, for example, a cavityside and a core side. The injection mold tools can come together to forma path for the molten plastic to fill. The first current collector 205and the second current collector 215 can be located in between thecavity side and core side of the injection mold tools and fixed in spacein their correct position with respect to the first cell holder 225 orthe second cell holder 230. A plastic material or molten plastic can beinjected into the injection mold tools and surround the first currentcollector 205 and the second current collector 215 and cool. Therebyforming an integrated cell holder product that includes at least onenon-conductive layer separating the first current collector 205 and thesecond current collector 215. The concept can be expanded to includeother overmolded features such as voltage sense lines 130 or temperaturesense lines 130.

The method 500 can include electrically isolating the first currentcollector 205 from the second current collector 215 using the isolationlayer 210 (ACT 520). For example, the isolation layer 210 can be coatedor laminated with a laminate material or laminate coating. In formingthe integrated current collector 115, the isolation layer 210 can bedisposed between the first current collector 205 from the second currentcollector 215 to separate and electrically isolate the first currentcollector 205 from the second current collector 215. The isolation layer210 can protect against shorting from the first and second currentcollectors 205, 215 (e.g., positive and negative current collectors 205,215).

One or more sense lines 130 can be formed on a surface or embeddedwithin the first current collector 205. For example, the sense lines 130can be disposed or embedded within the first current collector 205 usinginjection molding. The one or more sense lines 130 can couple with orconnect to at least one of the first current collector 205 or the secondcurrent collector 215. The first current collector 205, the secondcurrent collector 215, and the one or more sense lines 130 can compriseat least one conductive material. For example, the sense lines 130 canbe formed or embedded within the first current collector 205, the secondcurrent collector 215, or both the first current collector 205 and thesecond current collector 215. The sense lines can include wiresconfigured to provide data or information corresponding to the batterycells 110, the first current collector 205, or the second currentcollector 215.

Apertures 240, 245, 250 for each of the first current collector 205,second current collector 215, and isolation layer 210 can be aligned.For example, the plurality of apertures 240 of the first currentcollector 205 can be aligned with respect to the battery cells 110. Theplurality of apertures 240 of the first current collector 205 can bealigned to expose positive terminals 320 of the plurality of cylindricalbattery cells 110 through the conductive layer a first current collector205 and couple with at least one surface of the first current collector205.

The plurality of apertures 245 of the isolation layer 210 can be alignedto expose the positive terminals 320 of the plurality of cylindricalbattery cells 110 through the isolation layer 210 to connect to at leastone surface of the first current collector 205.

The plurality of apertures 250 of the second current collector 215 canbe aligned to expose the positive terminals 320 of the plurality ofcylindrical battery cells 110 through the second conductive layer 215.For example, each of the positive terminals 320 of the plurality ofcylindrical battery cells 110 can be positioned such that they extendthrough at least one of the plurality of apertures 250 of the secondcurrent collector 215 to connect to at least one surface of the firstcurrent collector 205. The plurality of apertures 240, 245, 250 can bealigned with respect to each other such that a throughway orunobstructed aperture is formed to expose the positive terminals 320 ofthe plurality of cylindrical battery cells 110 for coupling with atleast one surface of the first current collector 205. The pluralities ofapertures 240, 245, 250 can be aligned by aligning the boundaries of theapertures 240, 245, 250 between the layers. The pluralities of apertures240, 245, 250 can be aligned by using a jig, setting mold or tool toalign between the layers.

The battery cells 110 can be aligned or arranged within the batteryblock 105 using a first cell holder 225 and a second cell holder 230.For example, the first cell holder 225 hold, house or align theplurality of battery cells 110 using a fourth plurality of apertures255. The second cell holder 230 can hold, house or align the pluralityof battery cells 110 using a fifth plurality of apertures 260. The firstcell holder 225 can be coupled with or include the first currentcollector 205, the isolation layer 210, and the second current collector215. The battery cells 110 can be disposed such that a first end or topsurface is couple with the first cell holder 225 and a second end orbottom surface is coupled with the second cell holder 230. Thus, thefirst cell holder 225 and the second cell holder 230 can arrange thebattery cells in place.

The method 500 can include mounting the integrated current collectordevice 115 to the battery cells 110 (ACT 525). For example, theintegrated current collector device 115, including the first currentcollector 205, the isolation layer 210 and the second current collector215, can be mounted or otherwise coupled with the plurality ofcylindrical battery cells 110. The integrated current collector device115 can be positioned to provide structural support to hold theplurality of cylindrical battery cells 110 in place relative to oneanother. For example, the first current collector 205 and the secondcurrent collector 215 can be mounted, disposed in, or embedded within inthe integrated current collector device 115 and onto the plurality ofbattery cells 110 for welding or bonding (or other fastening) to thepositive and negative terminals respectively, of the plurality ofbattery cells 110. The integrated current collector device 115 can becoupled with, disposed on, or positioned in contact with a top end orfirst end of each of the plurality of battery cells 110.

The method 500 can include electrically connecting current collectorwith battery cells 110 (ACT 530). For example, the first currentcollector 205 can electrically couple with positive terminals 320 of theplurality of cylindrical battery cells 110 at first ends of theplurality of cylindrical battery cells 110 at the first ends of theplurality of cylindrical battery cells 110. The second current collector215 can electrically couple with negative terminals 325 of the pluralityof cylindrical battery cells 110 at the first ends of the plurality ofcylindrical battery cells 110. A positive terminal 320 of each of aplurality of battery cells 110 can be coupled with a surface or portionof the first current collector 205 through a positive wirebond 305. Thewirebond 305 can extend from the positive terminal 320 of each of aplurality of battery cells 110, though one or more of the apertures 240,245, 250, 255 and couple with the first current collector 205. Forexample, a wirebonding tool can attach or connect a bondhead or end of awirebond 305 to or near a center of a positive terminal 320 of thebattery cell 110, and another bondhead or end of the wirebond 305 to anuncoated or uninsulated surface of the first current collector 205. Awirebonding tool can access the positive terminal 320 of the batterycell 110 exposed by one or more of the apertures 240, 245, 250, 255 andcan connect one end of a wirebond 305 to the positive terminal 320. Thewirebonding tool can connect another end of the wirebond 305 to asurface of an uncoated or uninsulated surface of the first currentcollector 205.

A negative terminal 325 of each of a plurality of battery cells 110 cancouple with a surface or portion of the second current collector 215through a negative tab 310. For example, the apertures 250 of the secondcurrent collector 215 can be formed having a negative tab portion 310that extends into each of the apertures 250. The negative tab portion310 can be positioned within a respective aperture 250 such that itcouples with or contacts a negative terminal 325 of a battery cell 110or couples or contacts negative terminals 325 from at least two batterycells 110. A wirebonding tool can access a rim 220 of a battery cell 110exposed by one or more of the apertures 240, 245, 250, 255 and canconnect one end of a wirebond to the rim 220. The wirebonding tool canaccess a negative tab 310 or other portion of the second currentcollector 215, and can connect to a surface of the negative tab 310 orother portion of the second current collector 215.

Information about the plurality of battery cells 110 can be collected bya BMU 140 via the one or more sense lines 130. The integrated currentcollector device 115 can hold the plurality of battery cells 110 inplace relative to one another. The BMU 140 can be coupled with theintegrated current collector device 115, a battery module 100 or batteryblock 105 through one or more BMU wires 145. For example, the BMU 140can be coupled with the sense lines formed in, disposed on, or embeddedwithin the integrated current collector device 115. The BMU 140 can be acomponent of or integrated with the integrated current collector device115, a battery module 100 or battery block 105 through one or more BMUwires 145. For example, the BMU 140 can be incorporated into theintegrated current collector device 115, during manufacture, such as butnot limited to, during the injection molding. At least one of atemperature sensor, a current sensor, and a voltage sensor can beincorporated into the integrated current collector device 115 during theinjection molding. The BMU 140 can be coupled with to transmit data toor receive data from the temperature sensor, the current sensor, or thevoltage sensor.

The integrated current collector device 115 having the first currentcollector 205 and the second current collector 215, their associatedsense lines 130 and battery cell holders 225, 230 can be incorporatedinto a single part or component that is ready to mount on battery cells110. Such a design can enable a single sided, top weld approach forbattery cells 110 to make electrical connections from one battery cell110 to another battery cell 110 from the rim 220 or top cap side. Singlesided welding for positive and negative connections can be comparativelyeasier to handle or perform than the dual sided approach, by simplifyingassembly processes for battery blocks 105 or battery modules 100. Asingle part, integrated current collector structure 115 can improvebattery cell to battery cell interconnection design, for instance bydecreasing the number of parts for connecting to battery cells 110, andisolating the first current collector 205 and the second currentcollector 215 while holding these and the battery cells 110 together.

The single part comprising the stacked configuration can incorporateprotective features including channels 150, routing vents, cutouts orapertures for vent gasses to escape through the top (e.g., to supportcertain types of battery cells, such as bottom vent cells). The batterycells 110 can be vented from a first surface or top surface of therespective battery cell 110. For example, the battery cells 110 can bevented from the same surface or side that both the positive and negativeweld connections are formed. The apertures formed on the first currentcollector 205, second current collector 215, and first cell holder 225can be sized based at least on an area needed for welding and in part onan area needed to vent gases to escape. Aspects of the first currentconductor 205 and the second current collector 215 are discussed hereinonly by way of limitation, and are not intended to be limiting in anyway. Instead of stacked layers (e.g., in the z direction), the firstcurrent collector 205 can comprise strips of conductors arranged in aparallel configuration along a first direction (e.g., in the xdirection), and the second current collector 215 can comprise strips ofconductors arranged in a parallel configuration along a second direction(e.g., in the y direction) different from the first direction.

FIG. 6, among others, depicts an example embodiment of a method 600 ofproviding a system to power an electric vehicle 405 is depicted. Themethod 600 can include providing a battery pack (ACT 605). The batterypack 440 can include a plurality of battery modules 100. Each of theplurality of battery modules 100 can include a plurality of batteryblocks 105. A first battery block 105 of the plurality of battery blocks105 can include a pair of battery block terminals 330, 335. The firstbattery block 105 can include a plurality of cylindrical battery cells110. Each of the plurality of cylindrical battery cells 110 can includea positive terminal 320 and a negative terminal 325. An integratedcurrent collector device 115 can be formed in a single structure. Theintegrated current collector device 115 can include a first currentcollector 205 having a conductive layer. The conductive layer of thefirst current collector 205 can couple the first current collector 205with positive terminals 320 of the plurality of cylindrical batterycells 110 at first ends of the plurality of cylindrical battery cells110. A second current collector 215 can include a conductive layer. Theconductive layer of the second current collector 215 can couple thesecond current collector 215 with negative terminals 325 of theplurality of cylindrical battery cells 110 at the first ends of theplurality of cylindrical battery cells 110. An isolation layer 210 canbe disposed between the first current collector 205 and the secondcurrent collector 215. The isolation layer 210 can electrically isolatethe first current collector 205 from the second current collector 215.The isolation layer 210 can bind the first current collector 205 withthe second current collector 215 to form the single structure of theintegrated current collector device 115. The integrated currentcollector device 115 can provide structural support to hold theplurality of cylindrical battery cells 110 in place relative to oneanother when the plurality of cylindrical battery cells 110 areelectrically connected with the first current collector 205 and thesecond current collector 215.

While acts or operations may be depicted in the drawings or described ina particular order, such operations are not required to be performed inthe particular order shown or described, or in sequential order, and alldepicted or described operations are not required to be performed.Actions described herein can be performed in different orders.

Having now described some illustrative implementations, it is apparentthat the foregoing is illustrative and not limiting, having beenpresented by way of example. Features that are described herein in thecontext of separate implementations can also be implemented incombination in a single embodiment or implementation. Features that aredescribed in the context of a single implementation can also beimplemented in multiple implementations separately or in varioussub-combinations. References to implementations or elements or acts ofthe systems and methods herein referred to in the singular may alsoembrace implementations including a plurality of these elements, and anyreferences in plural to any implementation or element or act herein mayalso embrace implementations including only a single element. Referencesin the singular or plural form are not intended to limit the presentlydisclosed systems or methods, their components, acts, or elements tosingle or plural configurations. References to any act or element beingbased on any act or element may include implementations where the act orelement is based at least in part on any act or element.

The phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including” “comprising” “having” “containing” “involving”“characterized by” “characterized in that” and variations thereofherein, is meant to encompass the items listed thereafter, equivalentsthereof, and additional items, as well as alternate implementationsconsisting of the items listed thereafter exclusively. In oneimplementation, the systems and methods described herein consist of one,each combination of more than one, or all of the described elements,acts, or components.

Any references to implementations or elements or acts of the systems andmethods herein referred to in the singular can include implementationsincluding a plurality of these elements, and any references in plural toany implementation or element or act herein can include implementationsincluding only a single element. References in the singular or pluralform are not intended to limit the presently disclosed systems ormethods, their components, acts, or elements to single or pluralconfigurations. References to any act or element being based on anyinformation, act or element may include implementations where the act orelement is based at least in part on any information, act, or element.

Any implementation disclosed herein may be combined with any otherimplementation or embodiment, and references to “an implementation,”“some implementations,” “one implementation” or the like are notnecessarily mutually exclusive and are intended to indicate that aparticular feature, structure, or characteristic described in connectionwith the implementation may be included in at least one implementationor embodiment. Such terms as used herein are not necessarily allreferring to the same implementation. Any implementation may be combinedwith any other implementation, inclusively or exclusively, in any mannerconsistent with the aspects and implementations disclosed herein.

References to “or” may be construed as inclusive so that any termsdescribed using “or” may indicate any of a single, more than one, andall of the described terms. References to at least one of a conjunctivelist of terms may be construed as an inclusive OR to indicate any of asingle, more than one, and all of the described terms. For example, areference to “at least one of ‘A’ and ‘B’” can include only ‘A’, only‘B’, as well as both ‘A’ and ‘B’. Such references used in conjunctionwith “comprising” or other open terminology can include additionalitems.

Where technical features in the drawings, detailed description or anyclaim are followed by reference signs, the reference signs have beenincluded to increase the intelligibility of the drawings, detaileddescription, and claims. Accordingly, neither the reference signs northeir absence have any limiting effect on the scope of any claimelements.

Modifications of described elements and acts such as variations insizes, dimensions, structures, shapes and proportions of the variouselements, values of parameters, mounting arrangements, use of materials,colors, orientations can occur without materially departing from theteachings and advantages of the subject matter disclosed herein. Forexample, elements shown as integrally formed can be constructed ofmultiple parts or elements, the position of elements can be reversed orotherwise varied, and the nature or number of discrete elements orpositions can be altered or varied. Other substitutions, modifications,changes and omissions can also be made in the design, operatingconditions and arrangement of the disclosed elements and operationswithout departing from the scope of the present disclosure.

The systems and methods described herein may be embodied in otherspecific forms without departing from the characteristics thereof. Forexample the voltage across terminals of battery cells can be greaterthan 5V. The foregoing implementations are illustrative rather thanlimiting of the described systems and methods. Scope of the systems andmethods described herein is thus indicated by the appended claims,rather than the foregoing description, and changes that come within themeaning and range of equivalency of the claims are embraced therein.

Systems and methods described herein may be embodied in other specificforms without departing from the characteristics thereof. For example,descriptions of positive and negative electrical characteristics may bereversed. For example, elements described as negative elements caninstead be configured as positive elements and elements described aspositive elements can instead by configured as negative elements.Further relative parallel, perpendicular, vertical or other positioningor orientation descriptions include variations within +/−10% or +/−10degrees of pure vertical, parallel or perpendicular positioning.References to “approximately,” “about” “substantially” or other terms ofdegree include variations of +/−10% from the given measurement, unit, orrange unless explicitly indicated otherwise. Coupled elements can beelectrically, mechanically, or physically coupled with one anotherdirectly or with intervening elements. Scope of the systems and methodsdescribed herein is thus indicated by the appended claims, rather thanthe foregoing description, and changes that come within the meaning andrange of equivalency of the claims are embraced therein.

What is claimed is:
 1. A system to power electric vehicles, comprising:a battery pack to power an electric vehicle, the battery pack comprisinga plurality of battery modules; each of the plurality of battery modulescomprising a plurality of battery blocks; a first battery block of theplurality of battery blocks having a pair of battery block terminals,the first battery block comprising a plurality of cylindrical batterycells; each of the plurality of cylindrical battery cells having apositive terminal and a negative terminal; an integrated currentcollector device formed in a single structure, the integrated currentcollector device comprising: a first current collector having aconductive layer, the conductive layer of the first current collectorcoupling the first current collector with the positive terminals of theplurality of cylindrical battery cells at first ends of the plurality ofcylindrical battery cells; a second current collector having aconductive layer, the conductive layer of the second current collectorcoupling the second current collector with the negative terminals of theplurality of cylindrical battery cells at the first ends of theplurality of cylindrical battery cells; and an isolation layer disposedbetween the first current collector and the second current collector,the isolation layer electrically isolates the first current collectorfrom the second current collector, the isolation layer binds the firstcurrent collector with the second current collector to form the singlestructure of the integrated current collector device; and the integratedcurrent collector device provides structural support to hold theplurality of cylindrical battery cells in place relative to one anotherwhen the plurality of cylindrical battery cells are electricallyconnected with the first current collector and the second currentcollector.
 2. The system of claim 1, comprising: the integrated currentcollector device includes a plurality of slots for holding the pluralityof cylindrical battery cells in place relative to one another.
 3. Thesystem of claim 1, comprising: one or more sense lines to connect thefirst current collector to a battery monitoring unit (BMU), the one ormore sense lines to convey information about the plurality ofcylindrical battery cells to the BMU.
 4. The system of claim 1,comprising: one or more sense lines to connect to the second currentcollector to a battery monitoring unit (BMU), the one or more senselines to convey information about the plurality of cylindrical batterycells to the BMU.
 5. The system of claim 1, comprising: the integratedcurrent collector includes a battery monitoring unit (BMU) embeddedwithin the isolation layer.
 6. The system of claim 1, comprising: theintegrated current collector includes at least one of a temperaturesensor, a current sensor or a voltage sensor embedded within theisolation layer.
 7. The system of claim 1, wherein the isolation layerincludes a dielectric material, a plastic material, an epoxy material, aglass-reinforced epoxy laminate material, a polypropylene flameretardant and electrically insulating material or a polycarbonate flameretardant and electrically insulating material.
 8. The system of claim1, comprising: the integrated current collector device coupled with thefirst ends of the plurality of cylindrical battery cells.
 9. The systemof claim 1, comprising: the first current collector having a pluralityof apertures aligned with a plurality of apertures defined on the secondcurrent collector.
 10. The system of claim 1, comprising: a battery packthat includes a plurality of integrated current collector devices, theintegrated current collector devices to spatially maintain thecylindrical battery cells relative to each other to at least meetcreepage-clearance requirements for the battery pack to support avoltage of at least 400 volts across a positive terminal and a negativeterminal of the battery pack.
 11. The system of claim 1, comprising: aplurality of channels in the integrated current collector device, theplurality of channels to vent gaseous release from the plurality ofcylindrical battery cells.
 12. The system of claim 1, comprising: thebattery pack disposed in the electric vehicle.
 13. The system of claim1, comprising: the battery pack disposed in the electric vehicle; thefirst current collector coupled with a first busbar of the electricvehicle to provide electric power from the battery pack to the electricvehicle; and the second current collector coupled with a second busbarof the electric vehicle to provide electric power from the battery packto the electric vehicle.
 14. A method of providing a system to powerelectric vehicles, the method, comprising: providing a battery pack topower an electric vehicle, the battery pack comprising a plurality ofbattery modules, each of the plurality of battery modules comprising aplurality of battery blocks, a first battery block of the plurality ofbattery blocks having a pair of battery block terminals; disposing aplurality of cylindrical battery cells in the first battery block, eachof the cylindrical battery cells having a positive terminal and anegative terminal; forming an integrated current collector device viainjection molding, the integrated current collector device having afirst current collector, a second current collector, and an isolationlayer disposed between the first current collector and the secondcurrent collector; electrically isolating, using the isolation layer,the first current collector from the second current collector in theintegrated current collector device; mounting the integrated currentcollector device, including the first current collector, the secondcurrent collector, and the isolation layer, to the plurality ofcylindrical battery cells, the integrated current collector deviceprovides structural support to hold the plurality of cylindrical batterycells in place relative to one another; electrically connecting thefirst current collector to the positive terminals of the plurality ofcylindrical battery cells at first ends of the plurality of cylindricalbattery cells, and electrically connecting the second current collectorto the negative terminals of the plurality of cylindrical battery cellsat the first ends of the plurality of cylindrical battery cells.
 15. Themethod of claim 14, comprising: connecting one or more sense lines to atleast one of the first current collector and the second currentcollector; and collecting information about the plurality of cylindricalbattery cells to convey to a battery monitoring unit (BMU) via the oneor more sense lines.
 16. The method of claim 14, comprising:incorporating a battery monitoring unit (BMU) into the isolation layerduring the injection molding.
 17. The method of claim 14, comprising:incorporating into the isolation layer at least one of a temperaturesensor, a current sensor and a voltage sensor during the injectionmolding.
 18. The method of claim 11, comprising: aligning a plurality ofapertures defined on the first current collector, with a plurality ofapertures defined on the second current collector.
 19. The method ofclaim 14, comprising: spatially maintaining the cylindrical batterycells relative to each other to at least meet creepage-clearancerequirements for the battery pack to support a voltage of at least 400volts across a positive terminal and a negative terminal of the batterypack.
 20. An electric vehicle, comprising: a battery pack to power anelectric vehicle, the battery pack comprising a plurality of batterymodules; each of the plurality of battery modules comprising a pluralityof battery blocks; a first battery block of the plurality of batteryblocks having a pair of battery block terminals, the first battery blockcomprising a plurality of cylindrical battery cells; each of theplurality of cylindrical battery cells having a positive terminal and anegative terminal; an integrated current collector device formed in asingle structure, the integrated current collector device comprising: afirst current collector having a conductive layer, the conductive layerof the first current collector coupling the first current collector withthe positive terminals of the plurality of cylindrical battery cells atfirst ends of the plurality of cylindrical battery cells; a secondcurrent collector having a conductive layer, the conductive layer of thesecond current collector coupling the second current collector with thenegative terminals of the plurality of cylindrical battery cells at thefirst ends of the plurality of cylindrical battery cells; and anisolation layer disposed between the first current collector and thesecond current collector, the isolation layer electrically isolating thefirst current collector from the second current collector, the isolationlayer binds the first current collector with the second currentcollector to form the single structure of the integrated currentcollector device; and the integrated current collector device providesstructural support to hold the plurality of cylindrical battery cells inplace relative to one another when the plurality of cylindrical batterycells are electrically connected with the first current collector andthe second current collector.